ICE Making Assembly for a Refrigerator Appliance

The present subject matter relates generally to refrigerator appliances, and more particularly to ice making assemblies for a refrigerator appliance.

Refrigerator appliances generally include a cabinet that defines one or more chilled chambers for receipt of food articles for storage. Typically, one or more doors are rotatably hinged to the cabinet to permit selective access to food items stored in the chilled chamber. Further, refrigerator appliances commonly include ice making assemblies mounted within an icebox on one of the doors or in a freezer compartment. The ice is stored in a storage bin and is accessible from within the freezer chamber or may be discharged through a dispenser recess defined on a front of the refrigerator door.

Certain conventional refrigerator appliances have icemakers that are designed to form clear ice, e.g., such as large craft ice cubes with improved clarity. Making clear ice often requires that the ice makers slow the freezing rate by insulating the icemaker to help maintain slightly higher localized temperatures in the icemaker enclosure. Additional heaters may be used to help control localized temperature inside of an insulated enclosure. However, these chamber heaters are additional parts added to the system that require an extra electrical connection, driving up the cost and complexity of system.

Accordingly, a refrigerator appliance with features for improved ice making would be desirable. More particularly, an ice making assembly that facilitates improved ice making temperature for forming clear ice with minimal cost and complexity would be particularly beneficial.

Aspects and advantages of the invention will be set forth in part in the following description, may be apparent from the description, or may be learned through practice of the invention.

In one exemplary embodiment, a refrigerator appliance defining a vertical direction, a lateral direction, and a transverse direction is provided, including a cabinet defining a chilled chamber, a door rotatably mounted to the cabinet and rotatable between a closed position enclosing the chilled chamber and an open position providing access to the chilled chamber, and an ice making assembly of the refrigerator appliance. The ice making assembly includes an icemaker frame assembly defining an ice making chamber, an ice tray mounted to the icemaker frame assembly and defining a plurality of mold cavities for receiving water that is formed into ice, a fill tube for selectively supplying the water into the ice tray, and a heating assembly comprising a heating element and a heat sink that are thermally coupled to the fill tube, wherein the heating element is selectively energized to heat the water flowing through the fill tube and the ice making chamber.

In another exemplary embodiment, an ice making assembly of a refrigerator appliance is provided. The ice making assembly includes an icemaker frame assembly defining an ice making chamber, an ice tray mounted to the icemaker frame assembly and defining a plurality of mold cavities for receiving water that is formed into ice, a fill tube for selectively supplying the water into the ice tray, and a heating assembly comprising a heating element and a heat sink that are thermally coupled to the fill tube, wherein the heating element is selectively energized to heat the water flowing through the fill tube and the ice making chamber.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

As used herein, the terms “first,” “second,” and “third” may be used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components. The terms “includes” and “including” are intended to be inclusive in a manner similar to the term “comprising.” Similarly, the term “or” is generally intended to be inclusive (i.e., “A or B” is intended to mean “A or B or both”). The term “at least one of” in the context of, e.g., “at least one of A, B, and C” refers to only A, only B, only C, or any combination of A, B, and C. In addition, here and throughout the specification and claims, range limitations may be combined and/or interchanged. Such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise. For example, all ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other. The singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise.

Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “generally,” “about,” “approximately,” and “substantially,” are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value, or the precision of the methods or machines for constructing or manufacturing the components and/or systems. For example, the approximating language may refer to being within a 10 percent margin, i.e., including values within ten percent greater or less than the stated value. In this regard, for example, when used in the context of an angle or direction, such terms include within ten degrees greater or less than the stated angle or direction, e.g., “generally vertical” includes forming an angle of up to ten degrees in any direction, e.g., clockwise or counterclockwise, with the vertical direction V.

The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” In addition, references to “an embodiment” or “one embodiment” does not necessarily refer to the same embodiment, although it may. Any implementation described herein as “exemplary” or “an embodiment” is not necessarily to be construed as preferred or advantageous over other implementations. Moreover, each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

provides a perspective view of a refrigerator applianceaccording to an exemplary embodiment of the present subject matter. Refrigerator applianceincludes a cabinet or housingthat extends between a topand a bottomalong a vertical direction V, between a first sideand a second sidealong a lateral direction L, and between a front sideand a rear sidealong a transverse direction T. Each of the vertical direction V, lateral direction L, and transverse direction T are mutually perpendicular to one another.

Housingdefines chilled chambers for receipt of food items for storage. In particular, housingdefines fresh food chamberpositioned at or adjacent second sideof housingand a freezer chamberarranged at or adjacent first sideof housing. As such, refrigerator applianceis generally referred to as a side-by-side refrigerator. It is recognized, however, that the benefits of the present disclosure apply to other types and styles of refrigerator appliances such as, e.g., a top mount refrigerator appliance, a bottom mount refrigerator appliance, or a single door refrigerator appliance. Consequently, the description set forth herein is for illustrative purposes only and is not intended to be limiting in any aspect to any particular refrigerator chamber configuration.

A refrigerator dooris rotatably hinged to an edge of housingfor selectively accessing fresh food chamber. In addition, a freezer dooris rotatably hinged to an edge of housingfor selectively accessing freezer chamber. Refrigerator doorand freezer doorare shown in the closed configuration in. One skilled in the art will appreciate that other chamber and door configurations are possible and within the scope of the present invention.

provides a front view of refrigerator applianceshown with refrigerator doorand freezer doorin the open position. As shown in, various storage components are mounted within fresh food chamberto facilitate storage of food items therein as will be understood by those skilled in the art. In particular, the storage components may include bins 134 and shelves. Each of these storage components are configured for receipt of food items (e.g., beverages and/or solid food items) and may assist with organizing such food items. As illustrated, binsmay be mounted on refrigerator doorand freezer dooror may slide into a receiving space in fresh food chamberor freezer chamber. It should be appreciated that the illustrated storage components are used only for the purpose of explanation and that other storage components may be used and may have different sizes, shapes, and configurations.

Referring now generally to, a dispensing assemblywill be described according to exemplary embodiments of the present subject matter. Dispensing assemblyis generally configured for dispensing liquid water and/or ice. Although an exemplary dispensing assemblyis illustrated and described herein, it should be appreciated that variations and modifications may be made to dispensing assemblywhile remaining within the present subject matter.

Dispensing assemblyand its various components may be positioned at least in part within a dispenser recessdefined on freezer door. In this regard, dispenser recessis defined on a front sideof refrigerator appliancesuch that a user may operate dispensing assemblywithout opening freezer door. In addition, dispenser recessis positioned at a predetermined elevation convenient for a user to access ice and enabling the user to access ice without the need to bend-over. In the exemplary embodiment, dispenser recessis positioned at a level that approximates the chest level of a user.

Dispensing assemblyincludes an ice dispenserincluding a discharging outletfor discharging ice from dispensing assembly. An actuating mechanism, shown as a paddle, is mounted below discharging outletfor operating ice or water dispenser. In alternative exemplary embodiments, any suitable actuating mechanism may be used to operate ice dispenser. For example, ice dispensercan include a sensor (such as an ultrasonic sensor) or a button rather than the paddle. Discharging outletand actuating mechanismare an external part of ice dispenserand are mounted in dispenser recess.

Referring again to, inside refrigerator appliance, freezer doormay include an ice dispensing systemthat generally includes one or more icemakers and ice storage binsthat are configured to form ice. In this regard, for example, ice dispensing systemmay define an ice making chamberfor housing ice making assemblies, storage mechanisms, and dispensing mechanisms. According to the illustrated embodiment, ice dispensing systemmay include dispensing assemblyand may have a main icemaker. In addition, ice dispensing systemmay include an icemaker for forming “craft ice” that is commonly large, clear cubes or spheres of ice for alcoholic or non-alcoholic drinks. For example, a user may access this craft ice by opening freezer doorand accessing storage bindirectly.

A control panelis provided for controlling the mode of operation. For example, control panelincludes one or more selector inputs, such as knobs, buttons, touchscreen interfaces, etc., such as a water dispensing button and an ice-dispensing button, for selecting a desired mode of operation such as crushed or non-crushed ice. In addition, inputsmay be used to specify a fill volume or method of operating dispensing assembly. In this regard, inputsmay be in communication with a processing device or controller. Signals generated in controlleroperate refrigerator applianceand dispensing assemblyin response to selector inputs. Additionally, a display, such as an indicator light or a screen, may be provided on control panel. Displaymay be in communication with controllerand may display information in response to signals from controller.

As used herein, “processing device” or “controller” may refer to one or more microprocessors or semiconductor devices and is not restricted necessarily to a single element. The processing device can be programmed to operate refrigerator applianceand dispensing assembly. The processing device may include, or be associated with, one or more memory elements (e.g., non-transitory storage media). In some such embodiments, the memory elements include electrically erasable, programmable read only memory (EEPROM). Generally, the memory elements can store information accessible processing device, including instructions that can be executed by processing device. Optionally, the instructions can be software or any set of instructions and/or data that when executed by the processing device, cause the processing device to perform operations.

Referring again briefly to, according to an exemplary embodiment, cabinetalso defines a mechanical compartmentat or near the bottomof the cabinetfor receipt of a hermetically sealed cooling system. In general, sealed cooling systemis configured for transporting heat from the inside of refrigerator applianceto the outside (e.g., by executing a vapor-compression cycle or another suitable refrigeration cycle). As is generally understood by those of skill in the art, the hermetically sealed systemcontains a working fluid, e.g., refrigerant, which flows between various heat exchangers of the sealed systemwhere the working fluid changes phases while transferring thermal energy.

In this regard, as understood by one having ordinary skill in the art, sealed systemmay include a compressor, a condenser, an expansion device, and one or more evaporators connected in series by a fluid conduit that is charged with a refrigerant. Within sealed system, refrigerant flows into the compressor, which operates to increase the pressure of the refrigerant. This compression of the refrigerant raises its temperature, which is lowered by passing the refrigerant through the condenser. Within the condenser, heat exchange with ambient air takes place so as to cool the refrigerant. A condenser fan may be used to pull air across the condenser, so as to provide forced convection for a more rapid and efficient heat exchange between the refrigerant within the condenser and the ambient air. Thus, as will be understood by those skilled in the art, increasing air flow across the condenser can, e.g., increase the efficiency of the condenser by improving cooling of the refrigerant contained therein.

An expansion device (e.g., an electronic expansion valve, capillary tube, or other restriction device) receives refrigerant from the condenser. From the expansion device, the refrigerant enters the evaporator. Upon exiting the expansion device and entering the evaporator, the refrigerant drops in pressure. Due to the pressure drop and/or phase change of the refrigerant, the evaporator is relatively cool. An evaporator fan is typically provided at each the evaporator, e.g., to force air across and around the at least one evaporator to transfer thermal energy from the air to the evaporator (and more particularly, to the working fluid or refrigerant therein).

In this manner, a flow of cooling air exits the evaporator and may be distributed to one or more of the chilled chambersand/or. Specifically, one or more ducts may extend between the mechanical compartmentand the chilled chambersand/orto provide fluid communication therebetween, e.g., to provide the chilled air from the hermetically sealed cooling system, e.g., from an evaporator thereof, to one or more of the chilled chambersand/or.

The sealed systemdescribed herein is provided by way of example only. Thus, it is within the scope of the present subject matter for other configurations of the refrigeration system to be used as well. For example, according to alternative embodiments, sealed systemmay include additional components, e.g., at least one additional evaporator, compressor, expansion device, and/or condenser. For example, refrigerator appliancemay have two or more split evaporators, e.g., one dedicated primarily to cooling fresh food chamberand one dedicated primarily to cooling freezer chamber. In addition, alternative plumbing configurations, valves, and flow regulators may be used to route refrigerant throughout sealed system.

Referring now specifically to, icemakerwill be described in more detail according to example embodiments of the present subject matter. According to the illustrated embodiment, icemakeris mounted to freezer doorof refrigerator appliance. As explained briefly above, formation of ice with improved clarity, e.g., craft ice, often requires freezing temperatures that are elevated relative to the chilled chamber where icemakeris located. For example, a common temperature for freezer chambermay be around 0°F, while ice with improved clarity is typically formed at temperatures around°F. Accordingly, aspects of the present subject matter are directed to features of icemakerthat may maintain a suitable climate for forming clear ice without additional heaters, costs, and complexity. Although an exemplary construction is described herein, it should be appreciated that variations and modifications may be made while remaining within the scope of the present subject matter.

As shown, icemakermay generally include an icemaker framethat is mounted to freezer door, e.g., within ice dispensing system. In general, icemaker frameis a substantially rigid structure that is fixed in position to freezer doorand which generally defines an ice making chamber(e.g., the same or similar as ice making chamber) where ice is formed. According to the illustrated embodiment, icemakermay further include an insulating layerthat is positioned at least partially around or within icemaker frame. In this regard, insulating layermay include one or more insulating panels, foam, or other structure that reduces heat transfer between ice making chamberand freezer chamber, thereby facilitating some independent temperature regulation within ice making chamber.

Icemaker framemay further include one or more structures that are coupled for supporting various components of icemakeras described herein. For example, icemakermay further include an ice traythat is rotatably mounted to icemaker frameand which defines a plurality of mold cavitiesfor receiving water that is formed into ice during the ice production process. In this regard, refrigerator appliancemay include a water fill tubethat may be used to selectively dispense water into mold cavitiesto facilitate ice formation. For example, water may be supplied to fill tubefrom a water supply system of dispensing assembly.

According to the illustrated embodiment, ice trayis a twistable ice tray that is distorted in order to facilitate the release of ice. In this regard, ice traymay be rotatable between a first position or the “home position” or “ice making position” (e.g., as shown for example in) where water fill tubemay be used to fill mold cavitieswith liquid water. During the harvest process, ice traymay be rotated within icemaker frameby a drive motor. Icemaker framemay further include a structural stop (not shown) that engages ice trayto prevent localized rotation at one or more locations, thus resulting in the twisting of ice tray. This position may be referred to herein generally as the “harvest position.” Accordingly, as drive motorcontinues to rotate ice tray, structural stop causes ice trayto twist and deform the mold cavitiesin a manner that releases the ice cubes. It should be appreciated that the present subject matter is equally applicable to ice making assemblies that utilize other ejection mechanisms, e.g., such as sweep arms, ejection plungers, etc.

In general, the temperature within ice making chamberis largely regulated by sealed systemof refrigerator appliance. In this regard, cool air generated by sealed systemmay be passed into freezer chamberwhere at least a portion of the cool air is directed into ice making chamber, e.g., through one or more apertures, louvers, fan systems, etc. Accordingly, absent additional means for regulating the temperature of ice making chamber, the temperature within ice making chambermay be substantially the same as freezer chamber. As noted above, this temperature may not be suitable for forming clear craft ice.

Accordingly, according to an example embodiment of the present subject matter, icemakermay include a heating assemblythat is in operative communication with controllerfor selectively regulating a temperature within ice making chamber. In this regard, as illustrated for example in, heating assemblyincludes a heating elementand a heat sinkthat are thermally coupled to fill tube. In this manner, controllermay selectively energize heating elementto heat the water flowing through fill tubeand/or the air within ice making chamber.

In general, heating elementmay be any suitable number, type, and configuration of heaters thermally coupled to fill tubeand/or ice making chamberfor adding thermal energy thereto. For example, heating elementmay be a thin resistive heater wrapped around fill tube. For example, heating elementmay include a silicone heating wirepositioned within a conductive foil. For example, conductive foilmay be flexible aluminum foil with adhesive applied to one or more sides to sandwich silicone heating wiretherebetween. The result is a thin, flexible sheet that may be energized by controllerto generate heat.

Moreover, heating elementmay be positioned at any suitable location for introducing heat into fill tube, water being dispensed from fill tube, or ice making chamberdirectly. For example, as illustrated, heating elementmay be positioned at a distal end of fill tube. For example, heating elementmay be wrapped around fill tubeto prevent water from freezing and clogging fill tube. In addition, as described in more detail below, heating assemblymay include features for harnessing heat from heating elementand using it to raise the temperature of ice making chamberto a suitable temperature for producing clear ice.

In this regard, heat sinkmay be thermally coupled to heating element, e.g., to provide improved surface area for convective heat transfer with the air in ice making chamber. In this regard, for example, fill tubemay pass through heat sinkor may otherwise be in thermal contact with heat sink. In this regard, as illustrated, heat sinkmay define an aperture or groovesthrough which fill tubemay be seated when heat sinkis installed. More specifically, as illustrated in, heat sinkmay include a first portionand a second portionthat are clamped onto fill tubeover heating element, e.g., via one or more mechanical fasteners. In addition, heating elementmay be positioned between heat sinkand fill tube, such that tightening mechanical fastenersensures good thermal contact between fill tube, heating element, and heat sink. In this manner, heating elementmay be used to heat both fill tubeand ice making chamber, resulting in fewer components, costs, etc.

It should be appreciated that heat sinkmay generally be formed from any suitably rigid and thermally conductive material. For example, according to the example embodiment, heat sinkis formed from a block of aluminum, though other suitably conductive materials may be used. In addition, heat sinkmay include additional features for improving heat exchange with air in ice making chamber, such as heat exchange fins. In addition, although heating assemblyis described herein as a passive system relying on natural convention, it should be appreciated that heating assemblymay further include one or more fans, louvers, or other flow regulating devices to facilitate circulation of relatively warm air. Other heat exchanger constructions are possible and within the scope of the present subject matter.

According to example embodiments, one or more temperature sensors may be used to provide useful feedback regarding the operation of heating assemblyand the ice making conditions of ice making chamber. For example, heating assemblymay include a heater temperature sensorfor measuring a heater temperature of heating assembly. This measured temperature may be used to ensure a safe operating temperature of heating element(e.g., to prevent melting fill tube) and may also be used to deduce the amount of thermal energy being added to ice making chamber. According to the illustrated embodiment, heater temperature sensormay be embedded in heat sink, though other methods of attachment and thermal engagement are possible and within the scope of the present subject matter. In addition, icemakermay include a chamber temperature sensorpositioned within ice making chamberfor measuring a chamber temperature of ice making chamber. In addition, heating assemblymay further include a thermal fuse (not shown) to shut off heating assemblyif it gets too warm.

As used herein, “temperature sensor” or the equivalent is intended to refer to any suitable type of temperature measuring system or device positioned at any suitable location for measuring the desired temperature. Thus, for example, temperature sensors,may each be any suitable type of temperature sensor, such as a thermistor, a thermocouple, a resistance temperature detector, a semiconductor-based integrated circuit temperature sensor, etc. In addition, temperature sensors,may be positioned at any suitable location and may output a signal, such as a voltage, to a controller that is proportional to and/or indicative of the temperature being measured. Although exemplary positioning of temperature sensors is described herein, it should be appreciated that refrigerator appliancemay include any other suitable number, type, and position of temperature, humidity, and/or other sensors according to alternative embodiments.

The measured temperature of heating assemblyand/or the measured chamber temperature may be used as feedback in regulating the operation of heating assemblyto achieve a target ice formation temperature. In this regard, for example, controllermay be in operative communication with one or both of heater temperature sensorand chamber temperature sensor. Controllermay be configured to receive a request to form clear ice. For example, a user may use control panelto request that the ice formation process be switched from a standard ice making process to the clear or “craft” ice making process. Notably, when clear ice is requested, controllermay energize heating assemblywhile dispensing water through fill tube (e.g., using a water supply valve of dispensing assembly).

Heating assemblymay remain energized as water is being dispensed to fill ice trayand afterwards to selectively heat ice making chamberto a desired temperature. In this regard, controllermay measure a temperature using at least one of heater temperature sensoror chamber temperature sensor. In addition, controllermay control the operation of heating assembly(e.g., by regulating the applied voltage) to heat chamber based at least in part on the measured temperature(s). In addition, heating assemblymay be used for the entirely different purpose of periodically clearing clogs in fill tubeor other desirable purposes.

As explained herein, aspects of the present subject matter are generally directed to an ice maker with a heating system and control algorithm to maintain slightly higher enclosure temperature by using one heater as both fill tube heater and enclosure heater. The fill tube heater may be used to heat both the tube and air around the ice maker in an insulated enclosure. The heater may be mounted on an aluminum heatsink with extended surfaces. The heatsink with the heater may then be clamped to the fill tube. The extended surface allows effective heating of the enclosure while minimizing the heater and tube temperatures.

The heatsink can also have a hole to fit a temperature sensor such as a thermistor. The thermistor temperature could be used to drive an algorithm to determine when to power on the heater. The heater may also comprise a thermal fuse to shut it off when it turns too hot. Additionally, a second temperature sensor could be mounted inside the enclosure to determine the air temperature away from the heater assembly and the software algorithm may be utilized to control the heater, considering the temperature of one or both sensors to determine when to power the heater.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.